Mouse over, or press on each number on the map below to learn more about each step in our process.
1. PIPE SUPPLYPipe joints are transferred from storage to the ready racks in preparation for beveling.
2. PIPE BEVELINGPipe facing machines with hydraulic power units bevel the pipe ends at angles appropriate to the pipe thickness. The beveling equipment is inserted into the pipe ends and locked in. Guards are placed into position before beveling begins.
3. MOVEMENT UP THE READY RACKAfter beveling, the pipes are manually moved through each remaining position on the ready rack prior to welding. Smaller diameter pipes are moved by hand while larger diameters are rolled using a lever. Chocks are fitted to hold the pipes in position.
- Weld Area Preparation Operators on each pipe end clean the weld area and prepare the bevel using pencil grinders, flapper disks, mechanical wire brushes and handheld grinders.
- Weld Preheating Operators preheat the pipe ends. When the required temperature is reached the pipe is ready for the welding sequence.
- Band Placement A welding band is attached to the pipe to be used down the line with the external welding machines.
4. MOVEMENT TO THE MAINLINEWhen the main pipe stalk has moved forward and is ready to take on the new joint, the preheat equipment is removed. The pipe is transported onto motorized rollers, which will align the joint with the trailing end of the pipe stalk. An internal line-up clamp is inserted and the new joint is brought into abutment with the pipe stalk at the first welding station.
- Alignment and Root Welding Station The line-up clamp is activated to fix the pipe ends into position. Fume extraction fans are activated then the first root-pass weld is run. The weld is cleaned using grinders and mechanical wire brushes. The signal is given that the joint is ready to move to subsequent weld stations.
- Pulling the Pipe During operation, each workstation on the line is indicated by a red light. As a station completes its task, the light turns to green. When all lights on the line are green, the pipeline is advanced to the next workstation. Once the “pipe is pulled” all lights return to red and work continues. The performance of each station is recorded for improvement actions.
5. FILL WELD STATIONSAll internal and external fill welds are performed in these stations, including the final cap weld, using external welding machines.
6. FILL WELD STATIONSAll internal and external fill welds are performed in these stations, including the final cap weld, using external welding machines.
7. FILL WELD STATIONSAll internal and external fill welds are performed in these stations, including the final cap weld, using external welding machines.
8. DRESSING & STENCILINGThe weld cap is dressed using a grinder and mechanical wire brush while identifying numbers are stenciled with paint or permanent marker next to the weld on both sides of the pipe.
9. NDT OPERATIONSAfter clearing all stations, the pipe joints are inspected by radiographic or ultrasonic methods to ensure the integrity of the welds.
10. CLOSED CYCLE BLAST CLEANING STATIONUsing Vacublast equipment, pipes are blasted clean to prepare them for adhesive/coating application.
11. INDUCTION HEAT/POWEDERED EPOXY/ADHESIVE APPLICATION STATIONThe appropriate offshore field joint coatings are applied in one or two stages to guard against corrosion.
13. COOLING STATIONSSometimes the pipe is quenched with water to cool it after the welding stations and coating stations to obtain a temperature that will allow subsequent steps.
14. PIPE HANDLING/ROLLER BOXINGOnce a stalk is complete, it is moved to an outside storage rack where it will be spooled onto the vessel.
15. FINAL WELDING & TIE-IN STATIONIn a shack located near the vessel, finished pipe stalks are welded to the trailing end of the pipe already spooled onto the vessel. The final weld is inspected and coated.